Strong, dimensionally stable object

Abstract

A strong, dimensionally stable object, such as a tooling fixture, is produced by providing a three dimensional, rapid free form fabricated object having a hollow internal cavity and flowing a strengthening material, such as an epoxy resin, into the internal cavity.

I claim: 
     
       1. An article comprising a stereolithographically produced structure of desirable geometry having a plurality of internal, interconnected cavities, said structure being made of a photocurable liquid; and a strengthening material comprising an epoxy resin within the cavities, said strengthening material having a viscosity of between about 1,000 centipoise and about 30,000 centipoise and being injected within the cavities at an injection pressure of less than about 100 psi at a rate of injection between about 0.5 in 3  /min and about 50 in 3  /min wherein the structure is cured to produce a strong, densely packed, dimensionally stable article of accurate dimension. 
     
     
       2. The article of claim 1 wherein a portion of the photocurable liquid is removed to expose the epoxy resin. 
     
     
       3. The article of claim 1 wherein the article is a checking gauge. 
     
     
       4. The article of claim 1 wherein the article further comprises an outer coating. 
     
     
       5. The article of claim 4 wherein the coating is a wear resistant material. 
     
     
       6. The article of claim 1 wherein the article is pressure packed. 
     
     
       7. A tooling fixture comprising: (a) a three dimensional, stereolithographically produced object shaped as a tooling fixture; and   (b) strengthening material comprising an epoxy resin, said strengthening material having a viscosity of between about 1,000 centipoise and about 30,000 centipoise injected into said object at an injection pressure of less than about 100 psi at a rate of injection between about 0.5 in 3  /min and about 50 in 3  /min wherein said object is cured to produce a strong, densely packed, dimensionally stable tooling fixture of accurate dimension.   
     
     
       8. The tooling fixture of claim 7 wherein said tooling fixture further comprises an external void which is filled with a reinforcing material. 
     
     
       9. The tooling fixture of claim 8 wherein the reinforcing material is a wear resistant material. 
     
     
       10. A three-dimensional rapid free form fabricated article comprising: (a) a stereolithographically produced structure having a plurality of internal, interconnected cavities, said structure being made of a photocurable liquid; and (b) a strengthening material within the cavities of said structure, wherein the structure is cured to produce a strong, dimensionally stable article. 
     
     
       11. The article of claim 10, wherein said strengthening material comprises epoxy resin. 
     
     
       12. The article of claim 10, wherein said strengthening material has a viscosity of between about 1,000 centipoise and about 30,000 centipoise. 
     
     
       13. The article of claim 10, wherein said article is a checking gauge. 
     
     
       14. The article of claim 10 wherein said article further comprises an outer coating. 
     
     
       15. The article of claim 14, wherein said coating is a wear resistant material. 
     
     
       16. The article of claim 10, said strengthening material being injected within the cavities at an injection pressure of less than 100 psi at a rate of injection between about 0.5 in 3  /min and about 50 in 3  /min. 
     
     
       17. The article of claim 16, wherein the rate of injection is between about 1 in 3  /min and about 10 in 3  /min. 
     
     
       18. The article of claim 10, said strengthening material being injected within the cavities at an injection pressure of less than 50 psi at a rate of injection between about 0.5 in 3  /min and about 50 in 3  /min. 
     
     
       19. The article of claim 18, wherein the rate of injection is between about 1 in 3  /min and about 10 in 3  /min. 
     
     
       20. The article of claim 10, wherein said plurality of internal, interconnected cavities form a honeycomb-like internal structure. 
     
     
       21. The article of claim 10, wherein said stereolithographically produced structure and said strengthening material comprise different materials. 
     
     
       22. A three-dimensional rapid free form fabricated article produced by a method comprising the steps of: (a) providing a three dimensional, rapid free form fabricated structure having a hollow external cavity and (b) flowing a strengthening material into the cavity, thereby forming a strong, dimensionally stable article. 
     
     
       23. The article of claim 22, wherein said strengthening material comprises epoxy resin. 
     
     
       24. The article of claim 22, wherein said strengthening material has a viscosity of between about 1,000 centipoise and about 30,000 centipoise. 
     
     
       25. The article of claim 22, wherein said article further comprises an outer coating. 
     
     
       26. The article of claim 25, wherein said coating is a wear resistant material. 
     
     
       27. The article of claim 22, wherein said hollow external cavity comprises a plurality of interconnected cavities. 
     
     
       28. The article of claim 27, wherein said plurality of interconnected cavities form a honeycomb-like structure. 
     
     
       29. The article of claim 22, wherein said three dimensional, rapid free form fabricated structure and said strengthening material comprise different materials. 
     
     
       30. A three-dimensional rapid free form fabricated article produced by a method comprising the steps of: (a) providing a three dimensional, rapid free form fabricated structure having a hollow internal cavity and (b) flowing a strengthening material into the cavity, thereby forming a strong, dimensionally stable article. 
     
     
       31. The article of claim 30, wherein said strengthening material comprises epoxy resin. 
     
     
       32. The article of claim 30, wherein said strengthening material has a viscosity of between about 1,000 centipoise and about 30,000 centipoise. 
     
     
       33. The article of claim 30, wherein said article further comprises an outer coating. 
     
     
       34. The article of claim 33, wherein said coating is a wear resistant material. 
     
     
       35. The article of claim 30, wherein said hollow external cavity comprises a plurality of interconnected cavities. 
     
     
       36. The article of claim 35, wherein said plurality of interconnected cavities form a honeycomb-like internal structure. 
     
     
       37. The article of claim 30, wherein said rapid free form fabricated structure is stereolithographically produced. 
     
     
       38. The article of claim 30, further comprising the step of removing the rapid free form fabricated structure. 
     
     
       39. The article of claim 30, wherein said three dimensional, rapid free form fabricated structure and said strengthening material comprise different materials. 
     
     
       40. A three-dimensional article produced by a method comprising the steps of: (a) stereolithographically producing a three dimensional, rapid free form fabricated object having a hollow internal cavity and (b) flowing a strengthening material into the cavity, thereby forming a strong, dimensionally stable article. 
     
     
       41. The article of claim 40, wherein said strengthening material comprises epoxy resin. 
     
     
       42. The article of claim 40, wherein said strengthening material has a viscosity of between about 1,000 centipoise and about 30,000 centipoise. 
     
     
       43. The article of claim 40, wherein said article further comprises an outer coating. 
     
     
       44. The article of claim 43, wherein said coating is a wear resistant material. 
     
     
       45. The article of claim 44, wherein said plurality of interconnected cavities form a honeycomb-like internal structure. 
     
     
       46. The article of claim 40, wherein said hollow external cavity comprises a plurality of interconnected cavities. 
     
     
       47. The article of claim 40, further comprising the step of removing the stereolithographically produced structure. 
     
     
       48. The article of claim 40, wherein said strengthening material has a viscosity of between about 4300 centipoise and about 20,000 centipoise.